Fuel pump assembly

ABSTRACT

A sender assembly that has a compact state, which may allow a pump assembly including the sender assembly to be easily inserted into an opening of a fluid tank. For example, the pump assembly may be insertable into the opening of the fluid tank while a longitudinal axis of the pump assembly remains coaxial with the opening. When in the compact state a rotatable arm and a float of the sender assembly may be entirely within or deformable to be within a predetermined envelope that has a radial extent less than the opening of the fluid tank to allow the sender assembly to be inserted straight into the opening. The predetermined envelope may be coaxial with the longitudinal axis and have a cross-section transverse to the longitudinal axis that matches the opening of the tank.

RELATED APPLICATIONS

This application is related to a commonly-assigned concurrently filedapplication, “Fuel Pump Assembly” (Attorney Docket No. NOTTP0129USA),which is hereby incorporated by reference in its entirety.

FIELD OF INVENTION

The present invention relates generally to fluid pumps, and moreparticularly to fuel pump assemblies with sender assemblies.

BACKGROUND

Vehicles, such as consumer cars and trucks, with combustion enginesoften include a gas tank and an electronic pump assembly within the gastank to pump gasoline. Often the gas tanks will include an annular holeat the top to receive the corresponding electronic pump assembly.

The electronic pump assemblies often include a sender unit to detect thelevel of gasoline in the gas tank. Previously known sender units aretypically difficult to install since some level detection components ofthe sender units extend radially beyond the annular hole of the gastank, which causes interference with the gas tank when inserting theelectronic pump assemblies into the annular hole.

SUMMARY OF INVENTION

The present invention provides a sender assembly that has a compactstate, which may allow a pump assembly including the sender assembly tobe easily inserted into an opening of a fluid tank. For example, thepump assembly may be insertable into the opening of the fluid tank whilea longitudinal axis of the pump assembly remains coaxial with theopening. When in the compact state a rotatable arm and a float of thesender assembly may be entirely within or deformable to be within apredetermined envelope that has a radial extent less than the opening ofthe fluid tank to allow the sender assembly to be inserted straight intothe opening. The predetermined envelope may be coaxial with thelongitudinal axis and have a cross-section transverse to thelongitudinal axis that matches the opening of the tank.

A wiper of the sender assembly may be movable beyond a maximum orminimum position away from the other, the rotatable arm may be flexible,and/or the rotatable arm may have a zig-zag shape. Any of the abovefeatures may be used individually or in combination with one another.

According to one aspect of the invention, a pump assembly extends alonga longitudinal axis. The pump assembly includes a cover at an externalend of the pump assembly, the cover including a flange that extendsradially outward of the longitudinal axis, an insertable end oppositethe external end along the longitudinal axis, a fluid pump disposedbetween the insertable end and the flange, and a sender assembly fordetecting a fluid level in the fluid tank, the sender assembly beingdisposed between the insertable end and the flange. The sender assemblyis configured to transition into a compact state where the insertableend and the flange would be able to move straight along the longitudinalaxis from a position where the insertable end initially enters anopening, with a radial extent that is less than the flange, to aposition where the flange engages the fluid tank.

According to another aspect of the invention, a sender assembly fordetecting a fluid level in a fluid tank. The sender assembly includes asender housing, a variable resistor with a positive end and a groundedend opposite the positive end, a rotatable arm that has a pivot end anda revolvable end that is rotatably fixed relative to the pivot end andconfigured to revolve about the pivot end, wherein the rotatable arm ispivotably mounted at a position that is fixed relative to the variableresistor at the pivot end such that the revolvable end is movablerelative to the sender housing, and a wiper that is rotatably fixedrelative to the pivot end such that the wiper revolves about the pivotend when the rotatable arm revolves about the pivot end, wherein thewiper is engageable with the variable resistor such that revolving thewiper about the pivot end in a first rotation direction between thepositive end and the grounded end progressively increases an electricalresistance, between the positive end and the grounded end, from aminimum resistance toward a maximum resistance or progressivelydecreases the electrical resistance from the maximum resistance towardthe minimum resistance. When the revolvable end revolves about the pivotend in the first rotation direction the wiper revolves about the pivotend in the first rotation direction, and the wiper is configured to stoprevolving in the first direction when the wiper reaches a first positionwhere the electrical resistance is one of the maximum resistance or theminimum resistance, the wiper is configured to be revolvable away fromthe first position to a second position where the electrical resistanceis the other of the maximum resistance or the minimum resistance, andthe wiper is configured to be revolvable to a third position, beyond thesecond position away from the first position, where the wiper would beat least partially disengaged from the variable resistor.

According to another aspect of the invention, a method of assembling atank assembly that includes a fluid tank and a pump assembly, whichincludes a flange spaced apart from an insertable end of the pumpassembly along a longitudinal axis and includes a sender assemblydisposed between the insertable end and the flange. The method includesinserting the insertable end axially along the longitudinal axis intothe opening until the flange engages the fluid tank, wherein theinsertable end and the flange move straight along the longitudinal axisfrom a position where the insertable end initially enters the opening toa position where the flange engages the fluid tank.

Any of the above aspects may be combined with any one or all of theother aspects.

The foregoing and other features of the invention are hereinafterdescribed in greater detail with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an oblique view of a vehicle including an exemplary fuel tankassembly with an exemplary fuel pump assembly.

FIG. 2 is an oblique view of the fuel pump assembly of FIG. 1.

FIG. 3 is an oblique exploded view of an insertable end of the fuel pumpassembly of FIG. 2.

FIG. 4 is a front view of the fuel pump assembly of FIG. 2 including anexemplary sender assembly.

FIG. 5 is a right side view of the fuel pump assembly of FIG. 4.

FIG. 6 is a top view of the fuel pump assembly of FIG. 4 including a topcover with a flange.

FIG. 7 is a front view of part of the fuel pump assembly with the senderassembly of FIG. 2.

FIG. 8 is a front view of the fuel pump assembly of FIG. 2 with thesender assembly in a minimum fuel state when a wiper of the senderassembly is in a maximum resistance position.

FIG. 9 is a front view of the fuel pump assembly of FIG. 8 with thesender assembly in an intermediate fuel state when the wiper is betweenthe maximum resistance position and a minimum resistance position.

FIG. 10 is a front view of the fuel pump assembly of FIG. 9 with thesender assembly in a maximum fuel state when the wiper is in the minimumresistance position.

FIG. 11 is a front view of the fuel pump assembly of FIG. 10 with thesender assembly in a compact state when a wiper of the sender assemblyis in a disengaged position.

FIG. 12 is a front view of the fuel pump assembly of FIG. 11 with awiper of the sender assembly engaging a stop.

FIG. 13 is an oblique exploded view of the fuel tank assembly of FIG. 1including a fuel tank with an opening, where the fuel pump assembly isin the compact state and is being inserted along a longitudinal axisinto the opening.

FIG. 14 is an oblique partially-exploded view of the fuel tank assemblyof FIG. 13, where the fuel pump assembly is partially inserted into theopening.

FIG. 15 is an oblique view of the fuel tank assembly of FIG. 14, wherethe fuel pump assembly is fully-inserted into the fuel tank, from theinsertable end to the flange.

DETAILED DESCRIPTION

The principles of this present application have particular applicationto automobile fuel tank assemblies with a fuel tank and a fuel pumpassembly that pumps fuel out of the fuel tank and detects a level offuel in the fuel tank, such as the level of gasoline in the fuel tank,and thus will be described below chiefly in this context. It will beappreciated that principles of this invention may be applicable to otherfluid tank assemblies with fluid tanks where it is desirable to detectlevels of fluid in the fluid tanks, such as in a fuel tank of anaircraft or another fluid tank.

Referring now in detail to the drawings, and initially to FIG. 1, avehicle 20 (e.g., a car—as shown in dashed lines, or another vehiclediscussed above) according to one embodiment is illustrated. In anotherembodiment, the vehicle is a truck or an aircraft.

The vehicle 20 includes a combustion engine assembly 22, a fuel tankassembly 24, and a dashboard readout 26. The fuel tank assembly 24includes a fuel tank 28 and a fuel pump assembly 30 attached to andinserted into the fuel tank 28 to pump fuel from the fuel tank 28 anddetect the level of fuel in the fuel tank 28.

The fuel pump assembly 30 (an example of a pump assembly) is fluidlyconnected to the combustion engine assembly 22 via a fuel line 40 (anexample of a fluid line) to provide fuel to the combustion engineassembly 22 so that the combustion engine assembly is able to providemotive power for the vehicle 20. Also, the fuel pump assembly 30 isoperably connected to the dashboard readout 26 via a communication line42 such that the dashboard readout 26 indicates the level of fuel in thefuel tank assembly 24 to a driver of the vehicle 20.

Turning to FIG. 2, the fuel pump assembly 30 is illustrated alone. Thefuel pump assembly 30 extends along a longitudinal axis A, and includesan insertable end 60 with a reservoir housing 62 and an external end 64that remains external to the fuel tank 28 when the insertable end 60 isdisposed entirely within the fuel tank 28, as shown in FIG. 1. The fuelpump assembly 30 includes a top cover 66 at the external end 64,retractable support rods 68, 70, and 72 attached to the top cover 66 andthe reservoir housing 62, a fuel pump 74 disposed between the top cover66 and the insertable end 60, and a sender assembly 76 fixed to thereservoir housing 62.

The top cover has a radial center disposed on the longitudinal axis andincludes a radial flange 78 and an insertable wall 80. The radial flange78 extends radially outward of the longitudinal axis beyond theinsertable wall 80 from a central body of the top cover 66 such that theinsertable wall 80 can fit into the fuel tank 28 (shown in FIG. 1) andradial flange 78 is engageable with an external face of the fuel tank 28when the insertable wall 80 is inserted.

The top cover 66 also includes a fuel outlet port 100 connectable to thefuel line 40 (shown schematically with dashed lines), a vent port 102for venting pressure or vacuum in the fuel tank 28, a return inlet port104, a sender plug 106 in communication with the sender assembly 76, anda fuel pump plug 108 in communication with the fuel pump 74.

The insertable end 60 has a radial center disposed on the longitudinalaxis A and is axially opposite the external end 64 along thelongitudinal axis A. For example, the longitudinal axis A extendsperpendicularly through the bottom of the reservoir housing 62 and thetop of the top cover 66 and the top cover is spaced from the reservoirhousing by the retractable support rods 68, 70, and 72.

The retractable support rods 68, 70, and 72 allow the reservoir housing62 and the top cover 66 to move toward one another so that the fuel pumpassembly 30 can axially expand and contract when placed into the fueltank 28 (shown in FIG. 1). Also, the retractable support rods 68, 70,and 72 are spring biased to urge the top cover 66 and the reservoirhousing 62 apart from one another.

The fuel pump 74 is disposed in the reservoir housing 62 between thedisposed between the insertable end 60 and the radial flange 78. Anoutlet of the fuel pump 74 is fluidly connected to the fuel outlet port100 by a fuel tube 110 so that the fuel pump 74 can provide fuel to thefuel line 40. An abrasion sleeve 112 circumscribes a length of the fueltube 110 to cover the surfaces of the fuel tube 110 that would otherwisebe contactable with the springs of the retractable support rods 68, 70,and 72 so that the fuel tube 110 is protected against wear caused by thefuel tube 110 repeatedly rubbing against the springs.

Turning briefly to FIG. 3, the fuel pump assembly 30 further includes anexternal filter 114 and an internal filter 116. The external filter 114and the internal filter 116 both include multilayered filtrationmaterial. For example, a coarse outer layer that separates relativelylarge debris from the fuel, a middle layer that separates debris thatpasses through the coarse layer, and a fine layer that separates fineparticles from the fuel.

The external filter 114 is flexible and external to an interior of thereservoir housing 62 and fluidly connectable to an external filter port118 (an example of a first input port) of the fuel pump 74 through athrough hole 130 in the reservoir housing 62. The internal filter 116 isdisposable within the interior of the reservoir housing 62 and fluidlyconnected to an internal filter port 132 (an example of a second inputport) of the fuel pump 74. When the fuel pump assembly 30 is assembled,the internal filter 116 is disposed within the interior of the reservoirhousing 62 and fluidly connected to the internal filter port 132, andthe external filter 114 is partially disposed in an external filtercavity 134 external to the interior of the reservoir housing 62.

Turning to FIG. 4, the portion of the external filter 114 protrudingradially from the reservoir housing 62 is configured to resilientlydeform so that the radially outermost extent is less than or about thesame as the reservoir housing 62. For example, as shown in dashed lines,the external filter 114 can be resiliently bent away from the radialflange 78 and extend radially inward of an imaginary envelope 136 (shownin dashed lines) that is cylindrical and extends axially from anoutermost periphery of the radial flange 78. In an embodiment, theimaginary envelope has a radial extent that is 10-40%, 15-30%, or 20-25%less than that of the flange. In the illustrated embodiment, theexternal filter 114 may bend 90° or approximately 90° so that theportion of the external filter 114 extending radially from the reservoirhousing 62 may be parallel or approximately parallel to the near wall ofthe reservoir housing 62; in other words, the external filter 114 maybend 90° or approximately 90° so that the portion of the external filter114 extending radially from the reservoir housing 62 may be parallel orapproximately parallel to the longitudinal axis A.

As also shown in dashed lines, the external filter 114 can beresiliently bent toward the radial flange 78 and have a radial extentless than that of the radial flange 78 and slightly larger than that ofthe imaginary envelope 136. In an embodiment, the external filter can bedisposed in a different location such that bending of the externalfilter is not necessary to have a radial extent less than the imaginaryenvelope 136. In another embodiment, the reservoir housing 62 and theexternal filter 114 are configured such that the external filter 114 isresiliently bendable toward the radial flange 78 and has a radial extentless than or equal that of the imaginary envelope 136. In oneembodiment, the external filter 114 can be resiliently bent toward theradial flange 78, not by hand, but by interaction of the external filter114 with a gas tank 28 as the fuel pump assembly 30 is inserted in anopening 220 of the fuel tank 28. The external filter 114 may bend 90° orapproximately 90° upon interaction with the gas tank 28 so that theportion of the external filter 114 extending radially from the reservoirhousing 62 may be parallel or approximately parallel to the longitudinalaxis A. In an embodiment, the external filter can be disposed in adifferent location such that bending of the external filter is notnecessary to have a radial extent less than the imaginary envelope 136.

Still referring to FIG. 4, the sender assembly 76 is illustrated in acompact state, which the sender assembly 76 is configured to transitioninto and out of, as will be discussed below with reference to FIGS.8-11. The sender assembly 76 is able to detect a fluid level in the fueltank 28 (shown in FIG. 1) and is disposed between the insertable end 60and the radial flange 78. The sender assembly 76 is fixed to a frontface of the reservoir housing 62. For example, the sender assembly 76 isfixed to a front face of the reservoir housing 62 to a lever 138 of thesender assembly 76 that is fixedly connected to a loop 140 protrudingradially from the front face of the reservoir housing 62. In anotherembodiment, the sender assembly is fixed to the reservoir housing inanother manner, such as with an adhesive or a mechanical fastener, or isfixed to another portion of the sender assembly between the insertableend and the flange.

The sender assembly 76 includes a sender housing 160 that forms a firststop surface 162 and a second stop surface 164, a variable resistor 166having a positive end 168 and a grounded end 170 opposite the positiveend 168, a rotatable arm 172, a wiper 174, and a float 176. The variableresistor 166 has silver contacts formed in an arcuate shape forengagement with the wiper 174. In an embodiment, another variableresistor is used to engage the wiper 174, such as a variable resistorwith gold or copper contacts.

The rotatable arm 172 has a pivot end 178 and a revolvable end 180 thatis rotatably fixed relative to the pivot end 178 and configured torevolve about the pivot end 178. The rotatable arm 172 is pivotablymounted at a position that is fixed relative to the variable resistor166 at the pivot end 178 such that the revolvable end 180 is movablerelative to the sender housing 160. For example, the rotatable arm 172is formed by a wire with a zig-zag shape including bent portions 200 and202 within a plane parallel to the longitudinal axis A and the pivot end178 is rotatably journaled to the sender housing 160.

The entire zig-zag shape extends out of the plane only a thickness ofthe wire. For example, as shown in FIGS. 4 and 5, the wire has athickness T and the zig-zag shape extends into the page illustratingFIG. 4 a depth equal to the thickness T.

Still referring to FIG. 4, the rotatable arm 172 is flexible such thatwhen the rotatable arm 172 is in the compact position the rotatable arm172 is resiliently bendable into a position (shown in dashed lines inFIGS. 2 and 4-6), where the rotatable arm 172 has a radial extent lessthan the radial flange 78 and is entirely within the imaginary envelope136. For example, the rotatable arm 172 is made of stainless steel andis resiliently bendable at each bent portion 200 and 202 so that therotatable arm 172 is able to reduce its radial extent within a givenplane transverse to the longitudinal axis A to be less than that of theradial flange 78.

In another embodiment, the rotatable arm is made of another flexiblematerial, such as aluminum. In a further embodiment, the rotatable armhas a radial extent less than the opening of the tank withoutresiliently deforming the rotatable arm.

The float 176 is coupled to the revolvable end 180 and is buoyant in thefuel so that the revolvable end 180 is able to move with the level offuel in the fuel tank 28. In an embodiment, the float is hollow and/ormade of a buoyant material.

Referring now to FIGS. 4-6, the float 176 is movable to a position wherethe float 176 is entirely radially inward of a radial extent of theradial flange 78 and the imaginary envelope 136, as shown in dashedlines. For example, the float 176 can be urged radially inward towardthe longitudinal axis A to fit within the imaginary envelope 136.

Turning to FIG. 7, the rotatable arm 172, the variable resistor 166(schematically shown), and the wiper 174 are shown in more detail. Thewiper 174 is rotatably fixed relative to the pivot end 178 such that thewiper 174 revolves about the pivot end 178 when the rotatable arm 172revolves about the pivot end 178, as will be discussed further belowwith reference to FIGS. 8-12. The wiper 174 is engageable with thevariable resistor 166 such that revolving the wiper 174 about the pivotend 178 in a clockwise rotation direction CW (e.g., when the float 176(shown in FIG. 8) lowers in the fuel tank 28 (shown in FIG. 13) withdiminishing fuel) between the positive end 168 and the grounded end 170progressively increases an electrical resistance, between the positiveend 168 and the grounded end 170, toward a maximum resistance.

Accordingly, revolving the wiper 174 about the pivot end 178 in acounter-clockwise rotation direction CW (e.g., when the float 176 raisesin the fuel tank 28 with increasing fuel) between the positive end 168and the grounded end 170 progressively decreases the electricalresistance toward a minimum resistance. In an embodiment, the electricalresistance progressively decreases when revolving the wiper in theclockwise rotation direction and progressively increases when revolvingthe wiper in the counter-clockwise rotation direction.

Still referring to FIG. 7, the rotatable arm 172 and the wiper 174 arein a position where the wiper 174 is entirely disengaged from thevariable resistor 166, 45° beyond a minimum resistance position of thewiper 174. In an embodiment, the wiper 174 is configured to rotatebetween 30° and 60° beyond the minimum resistance position or beyond themaximum resistance position to be at least partially disengaged orentirely disengaged from the variable resistor.

The wiper 174 includes contact pins 204 and 206 (schematically shown),which are configured to engage the variable resistor 166 such that whenthe contact pins 204 and 206 move from the grounded end 170 to thepositive end 168 the resistance progressively increases since moreresistive material would be along the current path from the positive end168 to the grounded end 170. Accordingly, an amount of current flowingfrom the positive end 168 to the grounded end 170 would decrease.Alternatively, as the contact pins 204 and 206 move from the positiveend 168 to the grounded end 170 the resistance progressively decreasessince less resistive material would be along the current path from thepositive end 168 to the grounded end 170. Accordingly, an amount ofcurrent flowing from the positive end 168 to the grounded end 170 wouldincrease.

FIGS. 8-12 illustrate movement of the wiper 174 with the rotatable arm172 at first clockwise CW (indicating fuel is diminishing) to the firststop surface 162 and then counter-clockwise CCW (indicating fuel isincreasing) toward the second stop surface 164. As shown in FIG. 8, thewiper 174 can move clockwise CW with the rotatable arm 172 until thewiper 174 reaches a maximum resistance position (indicating the fueltank 28 (shown in FIG. 13) is empty) where the wiper 174 contacts thefirst stop surface 162. As shown in FIGS. 9 and 10, the wiper 174 canmove counter-clockwise CCW with the rotatable arm 172 until the wiper174 reaches the minimum resistance position (indicating the fuel tank 28is full).

As shown in FIG. 11, the wiper 174 can continue moving counter-clockwiseCCW with the rotatable arm 172 beyond the minimum resistance positionaway from the maximum resistance position, to a disengaged positionwhere the rotatable arm is in the compact position, just before thewiper 174 engages the second stop surface 164.

FIG. 12 illustrates that the wiper 174 can continue movingcounter-clockwise with the rotatable arm 172 to engage the second stopsurface 164. In an embodiment, the second stop surface is configured toabut the wiper when the rotatable arm reaches the compact position sothat the rotatable arm is prevented from rotating counter-clockwise CCWbeyond the compact position.

FIGS. 13-15 show the fuel pump assembly 30 being aligned with theopening of the fuel tank 28 and inserted into an opening 220 of the fueltank 28. The fuel pump assembly 30 is in the compact state and theinsertable end 60 and the radial flange 78 are in alignment with thelongitudinal axis A, which is coaxial with a center axis of the opening220, which is sized to receive the insertable wall 80 of the fuel pumpassembly 30. The radial flange 78 and the insertable end 60 are movedstraight along the longitudinal axis A from a position where theinsertable end 60 initially enters an opening 220 to a position wherethe radial flange 78 engages the fuel tank 28.

The radial centers of the insertable end 60 and the top cover 66 remaindisposed on the longitudinal axis A throughout the axial movement of theradial flange 78 and the insertable end 60, without tilting the radialflange 78 and without tilting the insertable end 60 relative to thelongitudinal axis A. For example, initially the external filter 114 isresiliently bent toward the radial flange 78 (as shown in FIG. 4 andmentioned above) as the insertable end 60 enters the opening 220.

Next, the lower bent portion 200 is resiliently bent as the upper bentportion 202 is urged radially inward by the radially inwardly facingsurface of the fuel tank 28 that forms the opening 220. As theinsertable end 60 continues into the fuel tank 28 along the longitudinalaxis A, the rotatable arm 172 moves out of engagement with the radiallyinwardly facing surface and the rotatable arm 172 is able to return toits natural shape.

Next, the bent portions 200 and 202 are resiliently bent as the float176 is urged radially inwardly by the radially inwardly facing surfaceof the fuel tank 28. As the insertable end 60 continues into the fueltank 28 along the longitudinal axis A, the float 176 moves out ofengagement with the radially inwardly facing surface and the rotatablearm 172 is able to return to its natural shape.

In an embodiment, the entire rotatable arm may resiliently deform,and/or other portions of the rotatable arm may deform, to allow the fuelpump assembly to fit into the opening of the fuel tank without tiltingthe fuel pump assembly relative to the longitudinal axis. In anotherembodiment, the external filter and/or the rotatable arm are configuredsuch that bending of such components is not needed to insert the fuelpump assembly straight into the opening of the fuel tank. In yet anotherembodiment, the insertable end and the radial flange are tilted at firstto insert the external filter, and movement of the insertable end andthe radial flange is entirely along the longitudinal axis immediatelyafter the external filter is inside the fuel tank.

According to one aspect of the invention, a pump assembly extends alonga longitudinal axis. The pump assembly includes a cover at an externalend of the pump assembly, the cover including a flange that extendsradially outward of the longitudinal axis, an insertable end oppositethe external end along the longitudinal axis, a fluid pump disposedbetween the insertable end and the flange, and a sender assembly fordetecting a fluid level in the fluid tank, the sender assembly beingdisposed between the insertable end and the flange. The sender assemblyis configured to transition into a compact state where the insertableend and the flange would be able to move straight along the longitudinalaxis from a position where the insertable end initially enters anopening, with a radial extent that is less than the flange, to aposition where the flange engages the fluid tank.

The insertable end may include a reservoir housing, the sender assemblymay be fixed relative to the reservoir housing and may further include arotatable arm that has a pivot end and a revolvable end that isrotatably fixed relative to the pivot end and configured to revolveabout the pivot end, wherein the rotatable arm has a first position thatindicates a first fluid level of the fluid tank, a second position thatindicates a second fluid level of the fluid tank, and a compact positionbeyond the second position away from the first position, and when therotatable arm is in the compact position, the sender assembly is in thecompact state.

The rotatable arm may be flexible such that when the rotatable arm is inthe compact position, the rotatable arm may be able to resiliently bendsuch that the rotatable arm has a radial extent, from the longitudinalaxis, that is less than the flange.

The sender assembly may further include a float coupled to therevolvable end, and the float may be movable to a position where thefloat is entirely radially inward of a radial extent of the flange.

The first position may indicate that the first fluid level is one of aminimum fluid level or a maximum fluid level, the second position mayindicate that the second fluid level is the other of the minimum fluidlevel or the maximum fluid level.

The pump assembly may further include an external filter external to aninterior of the reservoir housing and fluidly connected to a first inputport of the fluid pump, and an internal filter within the interior ofthe reservoir housing and fluidly connected to a second input port ofthe fluid pump.

A first radial center of the insertable end and a second radial centerof the flange may be disposed on the longitudinal axis, and when thesender assembly is in the compact state the first radial center and thesecond radial center may be able to remain on the longitudinal axis andmove straight along the longitudinal axis from the position where theinsertable end initially enters the opening, to the position where theflange engages the fluid tank.

The pump assembly may further include a fuel tube fluidly connecting anoutlet of the fluid pump with an outlet port of the cover.

The pump assembly may further include an abrasion sleeve circumscribinga length of the fuel tube.

The pump assembly may be a fuel pump assembly for attachment to a fueltank of a vehicle.

A fuel tank assembly for a vehicle may include the fuel pump assemblyand the fuel tank, and the fuel pump assembly may be attached to thefuel tank such that the insertable end of the fuel pump assembly iswithin the fuel tank and the flange is engaged with the fuel tank.

According to another aspect of the invention, a sender assembly fordetecting a fluid level in a fluid tank. The sender assembly includes asender housing, a variable resistor with a positive end and a groundedend opposite the positive end, a rotatable arm that has a pivot end anda revolvable end that is rotatably fixed relative to the pivot end andconfigured to revolve about the pivot end, wherein the rotatable arm ispivotably mounted at a position that is fixed relative to the variableresistor at the pivot end such that the revolvable end is movablerelative to the sender housing, and a wiper that is rotatably fixedrelative to the pivot end such that the wiper revolves about the pivotend when the rotatable arm revolves about the pivot end, wherein thewiper is engageable with the variable resistor such that revolving thewiper about the pivot end in a first rotation direction between thepositive end and the grounded end progressively increases an electricalresistance, between the positive end and the grounded end, from aminimum resistance toward a maximum resistance or progressivelydecreases the electrical resistance from the maximum resistance towardthe minimum resistance. When the revolvable end revolves about the pivotend in the first rotation direction the wiper revolves about the pivotend in the first rotation direction, and the wiper is configured to stoprevolving in the first direction when the wiper reaches a first positionwhere the electrical resistance is one of the maximum resistance or theminimum resistance, the wiper is configured to be revolvable away fromthe first position to a second position where the electrical resistanceis the other of the maximum resistance or the minimum resistance, andthe wiper is configured to be revolvable to a third position, beyond thesecond position away from the first position, where the wiper would beat least partially disengaged from the variable resistor.

The wiper may be in the third position such that the wiper is at leastpartially disengaged from the variable resistor.

The wiper may be entirely disengaged from the variable resistor.

The wiper may be configured to rotate about the pivot end anywhere from30° to 60° beyond the second position to reach the third position.

The sender housing may form a first stop surface and a second stopsurface, and the first stop surface may be configured to stop the wiperin the first position, and the second stop surface may be configured tostop the wiper in the third position.

The rotatable arm may be formed by a wire with a zig-zag shape within aplane parallel to the longitudinal axis.

A pump assembly may include the sender assembly and a fluid pump.

According to another aspect of the invention, a method of assembling atank assembly that includes a fluid tank and a pump assembly, whichincludes a flange spaced apart from an insertable end of the pumpassembly along a longitudinal axis and includes a sender assemblydisposed between the insertable end and the flange. The method includesinserting the insertable end axially along the longitudinal axis intothe opening until the flange engages the fluid tank, wherein theinsertable end and the flange move straight along the longitudinal axisfrom a position where the insertable end initially enters the opening toa position where the flange engages the fluid tank.

The pump assembly may be a fuel pump assembly and the fluid tank may bea fuel tank for an automobile.

Any of the above aspects may be combined with any of the other aspects.Also, any of the above features may be combined with any of the aboveaspects and/or any of the other above features.

Although the invention has been shown and described with respect to acertain embodiment or embodiments, it is obvious that equivalentalterations and modifications will occur to others skilled in the artupon the reading and understanding of this specification and the annexeddrawings. In particular regard to the various functions performed by theabove described elements (components, assemblies, devices, compositions,etc.), the terms (including a reference to a “means”) used to describesuch elements are intended to correspond, unless otherwise indicated, toany element which performs the specified function of the describedelement (i.e., that is functionally equivalent), even though notstructurally equivalent to the disclosed structure which performs thefunction in the herein illustrated exemplary embodiment or embodimentsof the invention. In addition, while a particular feature of theinvention may have been described above with respect to only one or moreof several illustrated embodiments, such feature may be combined withone or more other features of the other embodiments, as may be desiredand advantageous for any given or particular application.

1. A pump assembly extending along a longitudinal axis, the pumpassembly including: a cover at an external end of the pump assembly, thecover including a flange that extends radially outward of thelongitudinal axis; an insertable end opposite the external end along thelongitudinal axis; a fluid pump disposed between the insertable end andthe flange; and a sender assembly for detecting a fluid level in a fluidtank, the sender assembly being disposed between the insertable end andthe flange; wherein the sender assembly is configured to transition intoa compact state where the insertable end and the flange would be able tomove straight along the longitudinal axis, which is coaxial with acenter axis of an opening of the fluid tank, from a position where theinsertable end initially enters the opening, with a radial extent thatis less than the flange, to a position where the flange engages thefluid tank, wherein the insertable end includes a reservoir housing; andwherein the sender assembly is fixed relative to the reservoir housingand further includes: a rotatable arm that has a pivot end and arevolvable end that is rotatably fixed relative to the pivot end andconfigured to revolve about the pivot end to move a wiper configured toengage a variable resistor, wherein the rotatable arm revolves to movethe wiper from a first position that indicates a first fluid level ofthe fluid tank, to a second position that indicates a second fluid levelof the fluid tank, and to a compact position beyond the second positionaway from the first position in which the wiper disengages with thevariable resistor; and wherein when the rotatable arm is in the compactposition, the sender assembly is in the compact state.
 2. (canceled) 3.The pump assembly of claim 1, wherein the rotatable arm is flexible suchthat when the rotatable arm is in the compact position, the rotatablearm is able to resiliently bend such that the rotatable arm has a radialextent, from the longitudinal axis, that is less than the flange.
 4. Thepump assembly of claim 1, wherein the sender assembly further includes:a float coupled to the revolvable end, wherein the float is movable to aposition where the float is entirely radially inward of a radial extentof the flange.
 5. The pump assembly of claim 1, wherein the firstposition indicates that the first fluid level is one of a minimum fluidlevel or a maximum fluid level, the second position indicates that thesecond fluid level is the other of the minimum fluid level or themaximum fluid level.
 6. The pump assembly of claim 1, wherein the pumpassembly further includes: an external filter external to an interior ofthe reservoir housing and fluidly connected to a first input port of thefluid pump; and an internal filter within the interior of the reservoirhousing and fluidly connected to a second input port of the fluid pump.7. The pump assembly of claim 1, wherein a first radial center of theinsertable end and a second radial center of the flange are disposed onthe longitudinal axis, and when the sender assembly is in the compactstate the first radial center and the second radial center are able toremain on the longitudinal axis and move straight along the longitudinalaxis from the position where the insertable end initially enters theopening, to the position where the flange engages the fluid tank.
 8. Thepump assembly of claim 1, wherein the pump assembly further includes: afuel tube fluidly connecting an outlet of the fluid pump with an outletport of the cover.
 9. The pump assembly of claim 7, further including:an abrasion sleeve circumscribing a length of a fuel tube that extendsfrom the cover to the fuel pump.
 10. The pump assembly of claim 1,wherein the pump assembly is a fuel pump assembly for attachment to thefluid tank which is a fuel tank of a vehicle.
 11. A fuel tank assemblyfor a vehicle, including: the fuel pump assembly of claim 10; and thefuel tank; wherein the fuel pump assembly is attached to the fuel tanksuch that the insertable end of the fuel pump assembly is within thefuel tank and the flange is engaged with the fuel tank. 12-20.(canceled)
 21. A pump assembly extending along a longitudinal axis, thepump assembly including: a cover at an external end of the pumpassembly, the cover including a flange that extends radially outward ofthe longitudinal axis; an insertable end opposite the external end alongthe longitudinal axis; a fluid pump disposed between the insertable endand the flange; and a sender assembly for detecting a fluid level in afluid tank, the sender assembly disposed between the insertable end andthe flange and including a rotatable arm that has a pivot end and arevolvable end that is rotatably fixed relative to the pivot end andconfigured to revolve about the pivot end to move a wiper configured toslidably engage a variable resistor to indicate the fluid level, whereinthe rotatable arm revolves from a first position that indicates a firstfluid level of the fluid tank, to a second position that indicates asecond fluid level of the fluid tank, and to a compact position beyondthe second position away from the first position in which the wiperdisengages from the variable resistor.
 22. The pump assembly of claim21, wherein the rotatable arm is flexible such that when the rotatablearm is in the compact position, the rotatable arm is able to resilientlybend such that the rotatable arm has a radial extent, from thelongitudinal axis, that is less than the flange.
 23. The pump assemblyof claim 21, wherein the sender assembly further includes: a floatcoupled to the revolvable end, wherein the float is movable to aposition where the float is entirely radially inward of a radial extentof the flange.
 24. The pump assembly of claim 21, wherein the firstposition indicates that the first fluid level is one of a minimum fluidlevel or a maximum fluid level, the second position indicates that thesecond fluid level is the other of the minimum fluid level or themaximum fluid level.
 25. The pump assembly of claim 21, wherein the pumpassembly further includes: an external filter external to an interior ofthe reservoir housing and fluidly connected to a first input port of thefluid pump; and an internal filter within the interior of the reservoirhousing and fluidly connected to a second input port of the fluid pump.